BUSINESS OPPURTUNITIES IN PLASTICS PROCESSING & ALLIED INDUSTRIES

BY

DR.SUBHAS CHANDRA
PROF. AND HEAD HLC

CENTRAL INISTITUTE OF PLASTICS ENGINEERING AND TECHNOLOGY

AHMEDABAD

STATUS OF PLASTICS INDUSTRIES

Global Industries Knowledge and Highly skill based High Growth due to enough scope of value adding to plastic products through innovative technology Facing Competition

ORIGIN OF PLASTICS POLYMER

Petroleum

Nature

All polymers are not plastics. Only less than 5% petroleum is consumed for plastics. Remaining petroleum is used for energy and fuel.

APPLICATION OF PLASTICS
In various walk of life
Clothing to Shelter, Transportation to Communication, Entertainment to Health Care, Agriculture to Packaging Production, Shipment and storing.

This is because of their advantageous properties, light weight high strength and use of processing and use.

APPLICATION OF PLASTICS
Rigid HDPE barrels are used for bulk chemical storage instead of steel drums.
Apart from conserving natural resources, use of plastics in these applications saves transportation fuel as plastics are substantially lighter than tin, glass or steel. Plastics is especially made use of in industries like the automobile & aviation, resulting in fuel efficiency.

APPLICATION OF PLASTICS
Safe drinking water packaged in PET bottles is a very common sight now-a-days.

They provide confidence to the consumer on the quality of water and help reduce waterborne diseases.

APPLICATION OF PLASTICS
Modern buildings and constructions use plastic doors, windows, floor and wall coverings instead of wooden ones, ultimately saving trees. In Agriculture, plastics are used in irrigation pipes, tubes, hoses to better the micro-irrigation system as well as in greenhouses, films, increasing productivity.

APPLICATION OF PLASTICS
The health care sector uses plastics in blood bags, tubing, heart catheters, IV fluid bags, disposable products (gowns, masks, syringes) because it is both hygienic as well as easier to handle than other materials.

CONSUMPTION OF PLASTICS IN MAJOR INDUSTRY SECTOR

IMPACT OF PLASTICS ON ENVIRONMENT

They are protecting the environment in many ways
Used for light packing material Used for Electrical / Thermal installation Used in automobile for saving fuel Used as plastics woods and help in saving forest.

Plastics help in conserving material resources by elimination of metal and other conventional material used in various sectors Which consumes far more energy and thus lead to greater consumption of fossil fuel.

NEGATIVE IMPACTOF PLASTICS ON ENVIRONMENT

1. Inspite of many positive effects of using plastic it has negative impact on environment. 2. This is due to only 2% of total plastics consumption which is used as a film in packaging sector and found to little after use. 3. Which is not due to plastics but due to indiscriminate throwing by user. 4. About 7 to 10 % of total municipal solid waste is generated from use of plastics and their littering has become serious concern.

PREFERRED MATERIAL
They are preferred material Light Weight Not expensive Not breakable Malleable for design purposes (electronics and houses) Flexible use purposes Ease of fabrications As a result growth of plastics per capita consumption is increasing every year and expected to reach 7 to 8 kg by the end of this year 2012 as against world average of 25 kg and 140 kg of advance country.

CONSUMPTION OF PLASTICS IN WORLD

CONSUMPTION OF DIFFERENT TYPES OF PLASTICS

DEMAND OF VARIOUS PLASTICS IN INDIA

PRODUCTION OF VARIOUS PLASTICS IN INDIA

CONSUMPTION OF DIFFERENT PLASTICS MATERIALS IN INDIA

INCREASING RATE OF PLASTICS CONTENT

FUTURE REQUIREMENTS

CAUSE OF POLLUTION
The cause of pollution in the environment

WHAT ARE THE ISSUES ?

1. Inspite of adopting recycling of plastics and bio-based plastics (in lesser extent) it is stated that generation of plastics waste by 2030 would be reaching 10 times more than the present generation plastics waste. 2. There is no easy option to adopt appropriate plastics recycling / management process know how for handling plastics waste. Disposal to land fill Incineration without energy recovery Mechanical recycling Chemical recycling Energy recovery 3. Selection of these processes is governed by A. Volume and leaching of modifiers - in land fill B. Results depend on quality of incineration - if it is burnt C. Depend on market and feasibility - for recycling.

SOLID WASTE DISPOSAL SITES (SWDS) PRODUCE GREENHOUSE GASES (GHG)

Methane (CH4) Biogenic carbon dioxide (CO2) Non methane volatile organic compounds (NMVOCs) Small amounts of nitrous oxide (N2O), nitrogen oxides (NOx) and carbon monoxide (CO)

PLASTICS SOLID WASTE IN LANDFILL

GREEN HOUSE GASES FROM LANDFILL

Simplified Landfill Methane Mass Balance Methane (CH4) produced (mass/time) = (CH4 recovered + CH4 emitted + CH4 oxidized)

CONSTRAINTS IN RECYCLING
1. Mechanical recycling Requires clean homogenous waste that can be re melted and extruded into new product. This is often used on industrial waste and scrap but far less economical on domestic waste. 2. Chemical recycling Requires expensive grinding and chemical break down to new products that may be other products or fuel. This is not cost effective and needs government supports.

3. Energy recovery The high calorie many plastics does however rendered them ideal feed stock for energy recovery. This is also a easy process can be possible through municipal incinerator or by generating fuel.

EFFICIENCY OF RECYCLING PROCESS

1. Melt efficient system for recycling is mechanical recycling only 15 % efficient. 2. Recovery of energy via modern zero discharge incinerator 85% efficient

However, cost effective should be decided based on the ultimately exact LCA study, whether recycling is cost effective over energy recovery.

LIFE CYCLE STAGES

Sustainability of plastics depend on the following criteria.
Design Materials Production Packaging and distribution Use and maintenance End of useful life

SUSTAINABILITY DEPENDS ON VARIOUS CRITERIA

Design : Durable, repairable Materials : Sustainable, recyclable, non toxic (hydro carbon) Production : Process efficient, natural energy (solar energy) driven, Waste and toxic free Distribution and packaging : Efficient, sustainable, compostable, recyclable Use and Maintenance : Safe to use and easy to repair, polymer may be acceptable but what about modifiers (Additives) End of useful life : product can be composted, recycled

REGULATIONS FOR SUSTAINABLE PLASTICS PRODUCTS

Regulations for conservation of fossil material, emission control and composting of bio material (low carbon foot-print) should be strictly fulfilled by sustainable material.

Plastic products also should be made by technologies which are upgraded from the view point of energy consumption regulations.

CAN THE PLASTICS BE SUSTAINABLE IN SUCH SITUATION

It can be sustainable if the appropriate measures are taken for improving the material, the process technology and other points

as applicable for sustainable products.

ENVIRONMENT FRIENDLY PLASTICS MATERIALS 1. In order to profit in the business uniquely

value added plastics are continually being

developed by manufacturers.

2. The

impact

of
for visible

emerging,
value across

sophisticated
addition the is plastics
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technologies prominently

material industry.

DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (PET)

1. The important development in the material world is the introduction of inexpensive, metallocene based polypropylene with PET like properties that are set to make in roads in hot fill packaging. 2. Highly efficient PET recycling technology for converting dirty post consumer bottles into recyclable PET flakes is encouraging plastics industries to compete in PET bottle manufacturing since these flakes are less costly than virgin material. 32

DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (PC)

The use of a poly carbonate co-polymer film that is scratch/chemical resistant and capable of with standing ten years weathering tests to form a paint less class A decorative finish is another striking innovation generating considerable excitements in the global automotive industry.

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DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (TPO)

The toughness range in vulcanized thermoplastics olefilm (TPOs) has increased considerably with the development of hi-tech ethylene propylene diene monomer (EPDM) rubber design consideration can be changed.

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DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (POLYESTERS)

Rigid rod, self reinforced polymer that eliminate the need for added fillers which providing properties considered impossible with traditional engineering plastics is another breakthrough achievement. Above all the advent of compounded, semi crystalline polyesters is creating a plethora of opportunities for plastics materials to replace metals across numerous applications.
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DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (PE)

New generation Bimodel PE technology has allowed the development of high density PE resins, which typically exhibit an order of magnitude higher SCG (Slow Crack Growth) resistance than unimodal PE resins at lower densities. Moreover, bimodal PEs higher density allows a higher pressure rating and reduced wall thickness. More tougher pipe is possible with these materials.
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DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (HALOGEN FREE)

The development of halogen free plastics material for fire retardant pipe is another emerging area for exploitation.

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DEVELOPMENT RELATING TO CONVENTIONAL MATERIAL (LONG CHAIN BRANCHING)

Improvement in barrier properties of polyethylene by introducing optimum level of long chain branching is drawing much attention of the scientists and technocrats now a days. This is done with the help of peroxides other layer can be avoided.

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PLASTICS BASED ON BIO BASED OR PETRO CHEMICAL BASEED

Should be designed to breakdown for complete assimilation by micro organism in a disposal infrastructure such as composting

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BIODEGRADABLE PLASTICS
1. Smart compostable and bio-degradable plastic (PLA) from corn is getting popularized in advanced countries like USA for packaging strawberries and tomatoes. It is claimed by some company that this package from corn will save the equivalent of 800,000 gallons of gasoline and reduce 11 million pounds of green house gas emissions. This switch over is being convinced, to the consumer because of skyrocketing cost of plastics made from oil. In order to remain competitive in this front since 2000 DuPont has been slowly replacing petrochemicals with ingredients like corn. Today about 83 percent of its products use petrochemicals. Another company in USA is commercializing a family of polymers PHA natural plastics made from renewable resources such as sugar and vegetable oils. The material can be palletized and compounded into formulations suitable for a broad range of applications.
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2.

3. 4. 5. 6.

7.

BIODEGRADABLE PLASTICS
1. Scientists at the university of Dublin have found a way to breakdown Styrofoam, the base of recyclers/ composters everywhere. Bacteria have been found that eat Styrofoam and turn it into usable plastics. (Fig. 1) 2. A few companies in Japan designed a substitute of

polyester bottles with excellent physical properties by

modifying Bionolle a biodegradable polyester, using a technique of stretch blow moulding. 3. Plastics with some speciality chemical used in agricultural film becomes embrittled at the end of use due to oxibiodegradation.
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Fig. 1 Styrofoam

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DEVELOPMENT OF BIO BASED PLASTICS In bio based plastic materials significant portion of the carbon is derived from a renewal resources like corn, soybens or other plant mass

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APPLICATIONS OF BIOBASED POLYMERS

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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (CHARACTERISTICS)

1. Over the past few years, a growing number of nano materials consisting of particles measuring a billionth of a

meter or less have been successfully commercialized.

2. These materials are easy to process and they offer increased strength, modulus and dimensional stability over conventionally filled composite at very low loading. 3. In additions, they provide lower permeability to moisture,

gas and hydrocarbon, as well as improvements in thermal

stability, heat distortion temperature flame & chemical resistance, surface quality and optical clarity.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (FACTORS GOVERN PROPERTIES)

1. The property development of nano composite materials depends

on the exfoliation or dispersion of nano particles in resin.

2. These all needs surface treatment of nano clays loading and application of dispersion energy.

3. For achieving super plastic properties in the product processing

machineries to be designed according to the need. This could be a wide area of opportunity. 4. Bio-based nano-fibres are also being used for low carbon composites.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (ALREADY DEVELOPED)

1. Certain polymer based compound is developed for film extrusion that incorporate organoclay hybrid (2% to 8%) loading via the compounding process. 2. Which exhibit properties as good as or better than those of typical mineral field of 20 to 30% loading. 3. The material achieves a four fold improvement in oxygen transmission rate over unfilled polymer providing excellent barrier properties against, moisture gases and fragrances. 4. This dramatic improvement in properties could be possible through special compounding techniques with correct processing/dispersion aids or mould release.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (APPLICATIONS) 1. The application of nano fillers based plastics can be extended to the rotational moulded product where the strength is less.

2. The lightweight structure of high strength can be produced for products like rotational moulded tanks. 3. The other applications include processing of interior and exterior trim for the transportation industry, packaging liners, housings for appliances and power tools, closures, containers, pipes conduits, fittings and fascia used in the construction industry and consumer goods.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (APPLICATIONS)

Micro cellular nanocomposite foam for the structural and insulation market is the another area where new product applications are yet to be developed in order to take the advantages of much higher structural strength and thermal insulation performance of the nano composite over the existing materials.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS 1. Development of antiballistic material from nanocomposite is slowly penetrating the market

in order to achieve twice the strength of

competitive materials at half the weight.

2. Thus the area of process development of a new

defense product out of nanocomposite materials

would be a promising area.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (PREVENTING SPREADING OF FIRE)

Another area of processing would be related to development of polymer based nanocomposite with advanced FR properties that delay ignition, reduce smoke emissions and eliminate slumping and dripping of the molten polymer by the formation of a strong stable char.
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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (THIN WALL STRUCTURE)

The nano filler based plastics can be used to

manufacture many items used in engineering

application

particularly

where

thin

wall

component of high strength is required. (Fig. 2)

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Fig. 2 Nano composite materials for thin wall components (Light, stiff and tough attributes well suited to a broad range applications)

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DEVELOPMENT OF NANOSTRUCTURED MATERIALS (MATERIAL TO REPEL WATER)

1. Recently a new material has been developed by a group of scientists which can at the same time attract and repel water. 2. These opposing characteristics have been obtained by assembling a nanostructured film made of alternating layer of positively and negatively

charged polymers and silica nanoparticles.

3. 4. This super plastic could be used in dry areas or to collect water. It also could be used elsewhere to decontaminate water or in biomedical applications to make microfluidic chips. (Fig. 3)
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Fig. 3 Drops of water on superhydrophilic multi layer surface patterned with hydrophilic regions.

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TECHNOLOGY REQUIREMENT
Technologies are basically being developed based on following requirements for making plastic products Energy Efficient and environment friendly plastic product Efficient manufacturing process for minimizing energy of production well engineered design reducing waste material cost as well as facilitating recycling

BENEFITS OF THE MODERN TECHNOLOGIES

1. The uptake of these cleaner technologies in the plastics industries is being driven by a number of pressures. These include restricted outlets of waste disposal, the availability of and cost reduction associated with cleaner processes and changing public perception of current industrial practices. The clean technologies offers financial benefits of improved yield reduced cost and greater profits. It also offers value in the aspects of environmental impact, enhanced investors appeal and consumer confidence. 57

2.

3.

4.

EFFICIENT MANUFACTURING PROCESS FOR MINIMIZING WASTE

Energy Efficient Production

1. Plastic processing is costly step in plastic product manufacturing. 2. Therefore, if some kind of innovation is introduced in the step of its manufacturing then cost can be controlled without much change in property value of the product. 3. Many companies at present adopted this technique and achieved a significant cost saving due to power used in the production process.
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ENERGY EFFICIENT PRODUCTION (APPLICATION OF PROCESSING AIDS)

1. In order to improve, the processing of plastics at present processing aids are used at significantly low level. 2. When it is used in low level it neither alters or detracts from the good mechanical properties associated with high strength plastics.

3. This additives can offer performance and cost advantages over comparable loading of other processing aids.
4. The processing aids in the new formulations eliminate melt fracture, can reduce extruder torque, and increase output. 5. It improves clarity and gloss in film products.
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ENERGY EFFICIENT PRODUCTION (PROCESSING AIDS IN FILM)

1. Due to increasing global competition in the market of film manufacturing its quality standard is also constantly improving towards high performance cost ratio. This ratio can not be achievable without properly balancing the following properties by suitable modification with additives. One side there is the competition of first productivity of film at the cost effective price and in the other side need of meeting quality. This could be possible only if suitable processing aids are added to plastics for reducing mixing time and hence mixing energy, better mill handling, faster extrusion, low heat build up, reducing die swell and achieving gloss and balanced bi-directional properties. Above all when a right kind or processing aid like fluorocarbon polymers is added to a polymer compound at relatively low loading it improves processability without adversely effecting physical properties.
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2. 3. 4.

5.

CONTROLLED DENSITY MOULDING

1. Controlled Density (CD) Moulding is an another emerging area of plastics processing.

2. This is low pressure injection moulding processing. In this process virtually any type of thermoplastics can be moulded.
3. Even unsorted, uncleaned mixed plastic waste can be injection moulded into CD panels and used in a variety of exciting and imaginative new applications like, concrete forms, roofing material, furniture, office environments.

4. Green houses, animal confinement structures, marine, steam houses, swimming pool decks, panels for toilets, irrigation channels and items used in transportation. (Fig. 4) 61

Fig. 4 Controlled density panels used in housing

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EXTRUSION TECHNOLOGY FOR MIXING RECYCLED PLASTICS WITH VIRGIN PLASTICS 1. Extrusion technology for mixing recycled plastics with virgin studies indicated that a blend of 25% flake provided a product of acceptable physical and visual quality. 2. The mix of flakes and pellets could be processed on the existing equipment without any modifications in equipment or process parameters. Some additional equipment would be required to mix the flakes of a higher ratio.
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RECYCLED WOOD/PLASTIC COMPOSITE

1. This is one of the prime uses for recycled plastic trash bags and waste wood fiber. 2. The composite material is used to produce building products such as decking door and window frames and exterior moulding. 3. Recycled wood/plastic composite lumber typically consists of 50 / 50 mix of wood fiber from recovered saw dust and waste plastics that include high density polyethylene PVC and others. 4. The materials is formed into both solid and hollow profile. (Fig. 5) 64

Fig no. 5 Recycled wood/plastic composite lumber

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GOOD MANUFACTURING FOR REDUCTION OF WASTE

1. 2. i. The plastics used in pharmaceuticals in applications demands zero wastage in processing because of high cost of production. Therefore the processing of such products are taken care of in such a way that following criteria are fulfilled. Critical dimensional variances, surface finish, gate vestige flash, and edge finish are constantly monitored by a camera.

ii. Mold cavity condition is checked iii. Part length and inner diameter and outer diameter tolerances for medical molding applications are seen. iv. Compatibility with 21 CFR part 11 for medical GMP compliance is observed (Fig.6) v. Overload, preprinted logos and their positioning and contaminates are checked.
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vi. Part presence and position for insert molding is monitored.

GMP COMPLIANCE PRODUCTS

Fig. 6 Ascertaining Quality within the 6-s range in good manufacturing practices

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GOOD MANUFACTURING FOR REDUCTION OF WASTE (USE OF ROBOTS)

It has been said that the robot installed for reduction of waste verification of quality, improve manufacturing efficiencies which does not involve creative judgment but merely require a repetitive process. (fig. 7)

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Fig. 7 Inmould labelling operation by Robot

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GOOD MANUFACTURING FOR REDUCTION OF WASTE

1. In addition to the above, in order to control the waste and variation in layer thickness of the extruded products (multi layer films). 2. The in-line control is attached to the machine for monitoring uniform thickness. 3. This thickness measurement is based on contactless in-line layer measurement of total thickness and multiple layers with sub-micron (m) precision. 4. The reflection techniques is used for measurement of in-line data for blow and cast film systems as well as for controlling the production of liquid or solid coatings even on nontransparent material. (Fig. 8)
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Fig. 8 Contactless layer measurement

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ENERGY EFFICIENT MACHINERIES

1. All the above - mentioned development of plastics processing is taking place in order to meet the challenges of competing better in the market. 2. The plastics processors are looking to suppliers for total solution to help them compete better in their market. 3. This invites not only the application of robot and the tooling, but also other equipment such as insert feeders, conveyors, parts finishing equipments, vision systems and stacking and pelletizing equipment.

4. These equipments are interfaced with robot of such quality that are easy to programme and use, and having more speed to reduce cycle time, cost and labour.
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ENERGY EFFICIENT MACHINERIES OF ROBOTS)

(USE

1. It has been seen that manual placement of inserts that takes 80 sec. cycle can be operated at 45 sec. by automatic operation. 2. The 6-axis robot is inter faced with the machine for material handling, machine tending and secondary operation such as

degating, deflashing, labeling, quality assurance packaging

and palletizing. 3. Some robot is made for a vision system, the multiple camera integrated work cell (Fig. 9) for injection moulded parts.
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Fig. 9 Vision system is a multiple camera Injection Moulding Robot/Work cell vision inspection system that enables the verification of part quality at the point of manufacture

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ENERGY EFFICIENT MACHINERIES (USE OF ROBOTS)

1. The system enables processors to automatically check and verify critical dimensional variance surface finish, gate vestige and flash, as well as edge finish. 2. The vision system can also be used for inspecting mold cavities, checking insert molding part presence and position and other functions. 3. There are also robots, which act with a downstream automation cell to perform secondary operation such as labeling, cooling delegating and laser making. The system can help in cost saving and in maintaining minimum downtime. 4. There are 7 axis robot system where standard pick and place cycle time of 0.37 sec. makes easy the processing of components at high 75 speed.

ENERGY EFFICIENT MACHINERIES (LESS MANPOWER)

In order to reduce the no. of man working on the extruder a swing control system is mounted.

This helps operators to work at die area while simultaneously programming the high out put extruder.

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ENERGY EFFICIENT MACHINERIES Further development of all electric injection

moulding machine has made a significant

impact in clean room manufacturing

technology. (Fig. 10)

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Energy consumption / production cycle

100 90 80 70 60 50 40 30 20 10 0

Loss in transportation : - loss of pressure in pipes and hoses - losses in valves - losses through flow restrictor Loss in transformation : efficiency rate of motors - mechanical losses - leakage of hydraulic pump
-

Work of clampingand injection unit hydraulic moulding machine

servo-electric moulding machine

Fig. 10. Comparison of servo electric molding machine with conventional machine

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SOLUTION FOR ISSUES OF DISPOSAL AND ACCUMULATION OF PLASTICS

1. Recycling (most plastics are recyclable ) 2. Composting / organic diversion Based on these development of engineered life cycle plastic products should be focused

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MECHANICAL RECYCLING
In order to get standard recycled plastic materials the waste material should be processed as per following steps.
1. 2. 3. 4. Collection Storage Conveyance Size reduction unit

5.
6. 7. 8. 9.

Sorting
Washing Drying Conditioning Process (chopping / shearing / rotating to achieve better flow properties) Re-granulation by extruder (plastication, homogenization , stabilization , melt filtration , re-granulation
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SOLUTION FOR SORTING OF PLASTIC WASTE MATERIAL

1. Automatic separation has been successfully practised in many advanced countries. (for post consumer materials such as plastics bags, beverage carton and tin can ) 2. Machinery for recycling of plastics such as film, carves and bottles is already developed in advanced countries as well as India. 3. PET bottles are collected and sorted by hand or machine and recycled.
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SCOPE OF MECHANICAL RECYCLING

1. Mechanical recycling is beneficial when product manufacturing, distribution and collection after use is integrated to recycling 2. Mechanical recycling should be encouraged up to 3 to 4 times depending on the retention of required properties of the material needed for the products used in critical applications and standardization of the material is a must. 3. Mixed recycled plastics should be used in non critical areas. 4. After third or fourth recycling the material should be diverted to chemical recycling.
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CHEMICAL RECYCLING OF PLASTICS WASTE HAS BEEN ALREADY ADOPTED BY MANY COUNTRIES

1. For generation of fuel 2. Not economical

3. Government support is required

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PLASTIC PRODUCTS (EITHER BIO BASED OR PETROCHEMICAL BASED)

They are designed in such way that they can be broken down for complete assimilation by micro organization in a disposal infrastructure such as composting

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BIODEGRADABLE PLASTICSThe

Chemistry
Oxo-Biodegradable
Carbon-chain polymers Peroxidation Carboxylic acids, alcohols, hydroxycarboxylic acids

Hydro-biodegradable

Hetero-chain polymers Hydrolysis ABIOTIC CONTROL

Carbohydrates, carboxylic acids, alcohols BIOASSIM ILATION

Bacteria, fungi, enzymes, etc Biomass + CO2 Humus

Tipping the scale in favor of the natural Bio-cycle!

VALUE ADDITION ON RECYCLED PLASTICS

The value addition on recycled plastics has necessitated the development of the recycling/reprocessing technology of plastics in the following areas. 1. Blending/alloying 2. Reaction extrusion for melt strength development 3. Development in compounding technology (nano compounding, through DCS) (Fig. 11) 4. Development of extruded products as a substitute of wood/metal in various shape (wood composite). 5. Recycling of foam 6. Chemical recycling Zero waste concept has necessitated the integration of recycling of plastics waste with the main production.
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VALUE ADDITION ON RECYCLED PLASTICS

1. World wide, the incineration industry has proven itself to phenomenally unpopular. be

2. Environmental group across the globe are resisting waste incineration and are insisting that government put a stop to the deadly practice of burning waste. 3. It has been reported that burning waste of any kind causes the emission of present organic pollutants like Dioxins and Furans. 4. Dioxin exposure is linked to a variety of health problems such as impairment of the nervous system, the endocrine system, and the reproductive system. 5. Thus a zero waste approach is becoming popular and recycling is getting a priority in the light of conservation strategy of precious plastics material.
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AVOIDING DIVERSION

If we have to avoid diversion then we must maximize the life of plastics for mechanical recycling by taking innovative steps for value addition

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Fig. 11 High performance compounding line

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WELL ENGINEERED DESIGN FOR REDUCING MATERIALS IN THE PRODUCT FOR FACILITATING RECYCLING Today design of plastic products is done in a way that would facilitate the followings: a) Retrieval of valuable material. b) Removal of contaminants. c) Collection and reuse of components with longer useful life.

The plastics used in information, medical and communication

technology are designed with such concepts and information that

they can be easily recycled.
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MSME SECTORS (PLASTICS) IN INDIA The Indian plastic industry is highly

fragmented comprising of more than 25000 units. 10-15 % can be classified as medium scale. All other units are small scale firms. The industry has a significant presence of the unorganized sector, which accounts for more than 70% of the industry turnover. Although these player are small but they operate profitably.
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TAX BENEFITS
More than 95% of the firms in the industry are partnership, proprietorship & private limited companies. These small companies get significant advantages in tax benefits. Thus these firms despite their size provide significant level of competition to organized sector companies which as a group making losses. Due to liberalization, globalization and privatization there has been a constant charge in petrochemical industries in India - facing tough competition.
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GROWTH POTENTIAL
The consumption of plastics in India is about 7-8kgs. Which is much lower than the global average of 25 kgs. and 30 kgs. in China. The projected growth rate for polymer consumption in India the will be 15 % which will consume 18.9 million tonnes of plastics by 2015. Whereas worldwide the plastics and polymer consumption will have an average growth rate of 5% and it will touch the figure of 227 million tonnes by 2015.
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COMPETITIVE MARKET
Growth and opening up of the market, entry of foreign players investment and unorganized and fragmented nature of the plastic industries put them in a critical situation. In one hand they have to produce product which should be at par with global players. On the other hand the sector is lacking structure that would boost competitiveness and professionalism at global level.

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DIFFERENT PROCESS TECHNOLOGIES FOR PLASTIC PRODUCTS

To manufacture finished products polymers are processed through various types of technologies namely :
Extrusion Injection Moulding Blow Moulding Roto Moulding Thermoforming Etc.
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REQUIREMENTS OF SKILLED MANPOWER

These processes require skilled manpower to operate the machine and supervise the overall operations.

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LABOUR INTENSIVE PROCESSING SECTOR

Work force distribution is given below :
Operator (skilled and Semiskilled 20%

Reserch and Development 1% Opprator Unskilled 35%

Maintancce and Mould Making 1%

Marketing and Trading 38%

Managari al 2% Supervisory 3%

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WORK FORCE REQUIREMENTS

60% of the work force is employed at low end (i.e. machined operator, technician and supervisor levels.) Out of the remaining 40%, 1% is involved in R&D activities the rest is involved in managerial, marketing and trading activities.

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TO INCREASE GROWTH OF THE SECTOR (contributing more than 6% towards 6000 products of MSME)
1.4 million for 2011-12 . 0.9 million for low end. 10000-15000 per year (at present). Demand is much more.

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CONCLUSION
The technologies discussed above and the

skilled requirement indicated in the text if

taken care of by the policy makers of the

Govt. the present consumption of plastics

will be increasing in many fold which will

help in boosting the economy of the

country.
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